Waste and overflow system for a bathtub

ABSTRACT

A waste and overflow system for a bathtub includes an overflow conduit having a threaded end and an overflow cap threaded at one end extending through the overflow opening in the bathtub into threaded engagement with the threaded end of the conduit. The other end of the overflow cap has a test cap portion removably connected thereto for closing off an overflow passage through the overflow cap during pressure testing of the system. The test cap portion is removable from the other end of the overflow cap upon completion of the system pressure test to open up the overflow passage through the overflow cap.

FIELD OF THE INVENTION

[0001] This invention relates to a waste and overflow system forhandling any overflow from a bathtub.

BACKGROUND OF THE INVENTION

[0002] A typical waste and overflow system for a bathtub includes astandard overflow elbow that is held in sealed engagement with the backside of the tub in line with the tub overflow opening by self-tappingscrews that extend through slots in a mounting bar overlying theoverflow opening adjacent the front side of the tub and through the tuboverflow opening into holes in a flange portion of the elbow.

[0003] When the waste and overflow system is initially installed, theelbow drain opening must be sealed in a fluid tight manner to permitpressure testing of the sanitary drainage system for leaks. Heretofore,this was typically done by inserting a gasketed test cap into the elbowdrain opening through the tub overflow opening and threading a screwthrough a mounting hole in the mounting bar to cause the screw to presstightly against the test cap to hold the test cap in sealing engagementwith the overflow elbow. After pressure testing is completed, the screwand test cap are removed and a cover plate is placed over the tuboverflow opening and held in place by a mounting screw extending throughthe cover plate and into threaded engagement with the mounting hole inthe mounting bar.

[0004] This particular system has the objection that it is timeconsuming to install both the drain elbow and test cap to insure a fluidtight seal during pressure testing of the system and then remove thetest cap and replace it with a cover plate.

SUMMARY OF THE INVENTION

[0005] The present invention is for a waste and overflow system for abathtub that is relatively easy to install and allows for pressuretesting of the system without having to install a separate test cap inthe drain opening of the drain overflow elbow or other overflow conduitafter installation. To that end, the drain overflow conduit is threadedfor ease of threadedly connecting a threaded end of an overflow cap tothe overflow conduit through the overflow opening in the tub. Theoverflow cap has an overflow passage that is initially closed by a testcap portion that is removably attached to the outer end of the overflowcap, thereby eliminating the need for having to install a separate testcap into the conduit overflow drain opening before pressure testing ofthe system.

[0006] In one form of the invention, the test cap portion is integrallyconnected to the outer end of the overflow cap by a frangible seam tofacilitate removal of the test cap portion from the overflow cap afterthe pressure test has been completed.

[0007] In another form of the invention, the test cap portion isattached to the outer end of the overflow cap by a leak-proof mechanicalconnection that permits easy removal of the test cap portion after thepressure test has been completed.

[0008] The overflow cap may have a handle protruding therefrom tofacilitate threading of the overflow cap into the overflow conduit.Also, a slot may be provided in the handle for insertion of ascrewdriver blade or other rod-like tool to facilitate tightening of theoverflow cap into the overflow conduit and, in the case of a frangibletest cap portion, prying off of the test cap portion after the systempressure test has been completed to provide an overflow outlet in theoverflow cap in communication with the overflow conduit.

[0009] Upon removal of the test cap portion, a locking ring may beattached to the overflow cap by providing a mechanical lockingconnection therebetween. In one embodiment of the invention disclosedherein, the mechanical locking connection includes tabs on the overflowcap that are received in slots or recesses in the locking ring. When thelocking ring is rotated in a locking direction, each tab rides uprespective ramps on the locking ring to lock the locking ring againstthe overflow cap. The locking ring has a cross bar with a mounting holetherein for securing a cover plate over the locking ring and tuboverflow opening using a mounting screw. However, it will be appreciatedthat other types of mechanical locking connections may be providedincluding standard type threaded connections between the overflow capand locking ring as well as between the overflow cap and test capportion.

[0010] To the accomplishment of the foregoing and related ends, theinvention, then, comprises the features hereinafter more fully describedand particularly pointed out in the claims, the following descriptionand annexed drawings setting forth in detail certain illustrativeembodiments of the invention, these being indicative, however, of butseveral of the various ways in which the principles of the invention maybe employed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In the annexed drawings:

[0012]FIG. 1 is an exploded view of one form of waste and overflowsystem for a bathtub in accordance with the present invention;

[0013]FIG. 2 is a side elevation view showing the waste and overflowsystem of FIG. 1 in final assembled condition with a drain pipeconnected to an overflow elbow;

[0014]FIG. 3 is an enlarged perspective view of the overflow cap of thewaste and overflow system of FIGS. 1 and 2;

[0015]FIG. 4 is a fragmentary perspective view of the waste and overflowsystem as seen from the left end of FIG. 2 with the test cap portion ofthe overflow cap removed;

[0016]FIG. 5 is a perspective view of the test cap portion after removalfrom the overflow cap as shown in FIG. 4;

[0017]FIG. 6 is an enlarged perspective view of a locking ring that isattached to the overflow cap of FIG. 4 after removal of the test capportion;

[0018]FIG. 7 is a top plan view of the locking ring of FIG. 6;

[0019]FIG. 8 is a perspective view of the waste and overflow systemsimilar to FIG. 4 but showing the locking ring attached to the overflowcap;

[0020]FIG. 9 is a perspective view of the waste and overflow systemsimilar to FIG. 8 but showing a cover plate attached to the lockingring;

[0021]FIG. 10 is an enlarged perspective view of another form ofoverflow cap in accordance with this invention which may be substitutedfor the overflow cap of FIGS. 1 and 2;

[0022]FIG. 11 is a perspective view of the overflow cap of FIG. 10 butwith the test cap portion of the overflow cap removed;

[0023]FIG. 12 is a perspective view of the test cap portion afterremoval from the overflow cap as shown in FIG. 11;

[0024]FIG. 13 is an enlarged perspective view of another form ofoverflow cap in accordance with this invention which includes amechanical locking connection between the test cap portion and the outerend of the overflow cap;

[0025]FIG. 14 is a fragmentary transverse section through the overflowcap and test cap portion of FIG. 13 as seen from the plane of the line14-14 thereof;

[0026]FIG. 15 is a perspective view of the test cap portion of FIGS. 13and 14 by itself after removal from the overflow cap; and

[0027]FIG. 16 is an enlarged top plan view of the test cap portion ofFIG. 15.

DETAILED DESCRIPTION OF THE INVENTION

[0028] One form of waste and overflow system 1 for a bathtub 2 accordingto the present invention is schematically shown in FIGS. 1 and 2. Thesystem 1 includes an overflow elbow or other drain conduit 3 having aninternally threaded end portion 4 and an overflow cap 5 having anexternally threaded end portion 6 that is designed to be insertedthrough an overflow opening 7 in the bathtub and threaded into theoverflow elbow 3 for securing the overflow elbow 3 against the back sideof the tub. Alternatively, the overflow elbow or other conduit could beexternally threaded and the end portion of the overflow cap internallythreaded if desired. Before threading the overflow cap 5 and overflowelbow 3 together, an overflow gasket 8 is inserted over the threaded endportion 7 of the overflow cap. Also, Teflon tape or pipe joint compound(not shown) should be used on the threads 9 of the overflow cap beforescrewing the overflow cap into the overflow elbow. As the overflow capis threaded into the overflow elbow, the gasket 8 is compressed betweenthe flange 10 surrounding the internally threaded end portion 4 of theoverflow elbow 3 and the back side of the tub to form a water-tight sealtherebetween as schematically shown in FIG. 2.

[0029] The overflow cap 5 has a radial flange 11 adjacent the outer endthereof that engages the front wall of the tub during tightening of theoverflow cap into the overflow elbow. Circumferentially spaced centeringtabs 12 (shown in FIG. 1) may be provided on the back side of the flange11 to prevent offset installations.

[0030] The overflow cap has an overflow passage 14 (see FIG. 14)extending from one end to the other that is initially closed by a testcap portion 16 removably attached to the outer end 15 of the overflowcap. This eliminates the need for having to install a separate test capinto the end portion 4 of the overflow elbow 3 before pressure testingthe system.

[0031] In the embodiment shown in FIGS. 1-4, the test cap portion 16 isintegrally molded to the outer end 15 of the overflow cap by a frangibleseam 17 (see FIG. 3) for ease of removal of the test cap portiontherefrom after the pressure test has been completed. Surrounding thetest cap portion 16 is a cylindrical rim 1 8. The test cap portion 16 isintegrally molded to the inner periphery of the cylindrical rim 18 bythe frangible seam 17, whereby when the test cap portion is broken outof the outer end of the overflow cap, the cylindrical rim forms anoverflow outlet 1 9 to the overflow passage 14 through the overflow cap(see FIG. 4).

[0032] Protruding outwardly from the test cap portion 16 is a handle 20which may be grasped by the installer to facilitate threading of theoverflow cap 5 into the overflow elbow 3. After the overflow cap istightly screwed into the overflow elbow and a drain pipe 21 (shown inFIG. 2) and other appropriate connections are made to the sanitarydrainage system, the system is ready for pressure testing using air orwater.

[0033] A slot 22 may be provided in the handle 20 for insertion of ascrewdriver blade or other rod-like tool (not shown) to facilitatetightening of the overflow cap 5 into the overflow elbow 3 and pryingoff the test cap portion 16 after the system has been pressure tested toprovide the overflow outlet 19 at the outer end of the overflow cap inthe manner previously described. The test cap portion 16 with integralhandle 20 is shown broken out by itself in FIG. 5.

[0034] After the test cap portion 16 has been completely broken out ofthe outer end of the overflow cap 5 as shown in FIG. 4, a locking ring25, shown in detail in FIGS. 6 and 7, is inserted over the cylindricalrim 18 of the overflow cap and locked in place as shown in FIG. 8. Inthe invention embodiment disclosed in FIGS. 1-9, a locking connection 26is provided between the locking ring and overflow cap which includes apair of locking tabs 27 and 28 on the cylindrical rim 18 of the overflowcap and a pair of locking ramps 29 and 30 on the locking ring, withlocking ring openings 31 and 32 adjacent the leading ends of the lockingramps for receipt of the locking tabs. The locking ring 25 is placedaround the cylindrical rim 18 of the overflow cap 5 by aligning the twotabs 27 and 28 on the cylindrical rim 18 with the locking ring openings31 and 32 and rotating the locking ring in a locking direction relativeto the overflow cap to ramp the locking ring up tight against theoverflow cap flange 11 as shown in FIG. 8. Extending outwardly fromopposite sides of the locking ring 25 are finger gripping arms 35 and 36to facilitate turning the locking ring relative to the overflow cap.Also, the flange portion 11 of the overflow cap 5 may have anon-circular periphery 37 for ease of turning of the overflow cap forunscrewing the overflow cap from the overflow elbow if desired.

[0035] The locking ring 25 has a cross member 40 containing a screw hole41 for receiving a screw 42 used to attach a cover plate 43 over thelocking ring and tub overflow outlet 19 as schematically shown in FIG.9.

[0036]FIGS. 10 and 11 show another form of overflow cap 50 in accordancewith this invention which may be utilized in place of the overflow cap 5in the system 1 shown in FIGS. 1 and 2. The overflow cap 50, like theoverflow cap 5, has a threaded end portion 51 that is designed to beinserted through the overflow opening 7 in the bathtub 2 and threadedlyconnected to the overflow elbow or other conduit 3 for securing theoverflow elbow against the back side of the tub as before. At the outerend of the overflow cap 50 is a radial flange 52 that engages the frontwall of the tub during tightening of the overflow cap into the overflowelbow and an overflow passage 53 (see FIG. 11) extending from one end tothe other that is initially closed by a test cap portion 54 that isintegrally molded to the outer end 55 of the overflow cap by a frangibleseam 56 for ease of removal of the test cap portion after the pressuretest has been completed.

[0037] A handle 57 is provided at the outer end of the overflow cap 50for grasping by the installer to facilitate threading of the overflowcap into the overflow elbow 3. However, the handle 57, instead of beingintegral with the test cap portion as shown in FIGS. 1-3, is permanentlyaffixed to opposite sides of the overflow outlet 58 at the outer end ofthe overflow cap 50, thus dividing the test cap portion 54 into twofrangibly removable test cap portion halves 60. This has the advantagethat a blind hole 61 may be provided in the handle 57 for attaching acover plate 43 to the overflow cap 50 using a screw 42 without the needfor a locking ring. Of course, in that event, the hole 61 in the handle57 can initially only extend part way through the handle so the handleis fluid-tight during pressure testing of the system. However, the endwall 62 of the blind hole 61 can be made thin enough that the screw 42can punch through the end wall during tightening of the screw within thehole after the pressure test has been completed.

[0038] To prevent the test cap portion halves 60 from falling into theoverflow outlet 58 during their removal from the outer end of theoverflow cap 50, the test cap portion halves are connected together by atab 65 extending transversely of the handle in axially outwardly spacedrelation therefrom (see FIGS. 10 and 12). The test cap portion 54 isshown by itself in FIG. 12 with its two halves 60 connected to oppositeends of the tab 65 after the test cap portion has been broken out of theoverflow cap 50.

[0039]FIGS. 13 and 14 show another form of overflow cap 70 in accordancewith this invention which is substantially the same as the overflow cap5 shown in FIGS. 1-4. However, the overflow cap 70, rather than having afrangible test cap portion as shown in FIGS. 1-4, has a separatelyformed test cap portion 72, shown by itself in FIGS. 15 and 16, thatincludes a mechanical locking connection 73 with the overflow cap thuspermitting selective attachment and detachment of the test cap portionfrom the overflow cap. This has the advantage that the test cap portion72 can be used with more than one overflow cap 70 if desired.

[0040] In the embodiment shown in FIGS. 13 and 14, the mechanicallocking connection 73 includes a pair of locking tabs 27 and 28 on thecylindrical rim portion 18 of the overflow cap and a pair of lockingramps 74 and 75 on the test cap portion 72, with locking ring openings76 and 77 adjacent the leading ends of the locking ramps (see FIGS. 15and 16) for receipt of the locking tabs, similar to the lockingconnection 26 between the locking ring 25 and overflow cap 5 shown inFIGS. 4-8. The test cap portion 72 is placed around the cylindrical rim18 of the overflow cap 70 by aligning the two tabs on the cylindricalrim with the test cap openings 76 and 77 and rotating the test capportion in a locking direction relative to the overflow cap to ramp thetest cap portion up tight against the overflow cap.

[0041] Protruding outwardly from the test cap portion 72 is a handle 80which may be grasped by the installer to facilitate turning of the testcap portion relative to the overflow cap. Alternatively, finger grippingarms 81 and 82 may be provided on opposite sides of the test cap portionto facilitate turning of the test cap portion relative to the overflowcap. A gasket 83 is disposed in a groove 84 on the under side of thetest cap portion 72 (see FIG. 14) to provide a fluid-tight seal with theupper end of the cylindrical rim 18 of the overflow cap 70 duringtightening of the test cap portion on the overflow cap.

[0042] After the system is pressure tested and the test cap portion 72has been removed by rotating the test cap portion in the unlockingdirection, a locking ring similar to the locking ring 25, shown indetail in FIGS. 6 and 7, may be inserted over the cylindrical rim 18 ofthe overflow cap 70 and locked in place as before for securing a coverplate over the locking ring and tub overflow opening using a mountingscrew in the manner previously described.

[0043] While only one type of mechanical locking connection is shown forselectively mechanically connecting both the test cap portion 72 and thelocking ring 25 to the overflow cap 70, it will be appreciated thatother types of mechanical locking connections may be utilized, includingfor example standard type threaded locking connections.

[0044] Although the invention has been shown and described with respectto certain embodiments, it is obvious that equivalent alterations andmodifications will occur to others skilled in the art upon the readingand understanding of the specification. In particular, with regard tothe various functions performed by the above described components, theterms (including any reference to a “means”) used to describe suchcomponents are intended to correspond, unless otherwise indicated, toany component which performs the specified function of the describedcomponent (e.g., that is functionally equivalent), even though notstructurally equivalent to the disclosed component which performs thefunction in the herein illustrated exemplary embodiments of theinvention. In addition, while a particular feature of the invention mayhave been disclosed with respect to only one embodiment, such featuremay be combined with one or more other features of other embodiments asmay be desired and advantageous for any given or particular application.

What is claimed is:
 1. A waste and overflow system for a bathtubcomprising an overflow conduit and an overflow cap having opposite ends,one of said ends of said overflow cap being threadedly connectable to anend of said overflow conduit to provide a fluid-tight seal therebetween,an overflow passage extending through said overflow cap from one end tothe other, and a test cap portion removably connected to the other endof said overflow cap for closing off said overflow passage duringpressure testing of the system, said test cap portion being removablefrom said other end of said test cap portion upon completion of thesystem pressure test to open up said overflow passage through saidoverflow cap.
 2. The system of claim 1 wherein said test cap portion isintegrally connected to said other end of said overflow cap by afrangible seam for ease of removal of said test cap portion from saidoverflow cap.
 3. The system of claim 2 further comprising a handleintegrally connected to said test cap portion to facilitate tighteningof said overflow cap.
 4. The system of claim 3 wherein said handle has aslot for receipt of a rod-like member for use in tightening saidoverflow cap.
 5. The system of claim 1 wherein said handle has a slotfor receipt of a rod-like member for use in breaking out said test capportion from said overflow cap.
 6. The system of claim 2 wherein ahandle extends across said overflow passage, said handle beingpermanently affixed to said other end of said overflow cap, and saidtest cap portion includes two test cap portion halves integrallyconnected to said other end of said overflow cap and opposite sides ofsaid handle by frangible seams for ease of removal of said test capportion halves from said other end of said overflow cap.
 7. The systemof claim 6 further comprising a tab having opposite ends integral withsaid test cap portion halves to prevent said test cap portion halvesfrom falling into said overflow passage upon removal of said test capportion halves from said other end of said overflow cap.
 8. The systemof claim 1 wherein said test cap portion is mechanically attachable anddetachable from said other end of said overflow cap.
 9. The system ofclaim 1 wherein said other end of said overflow cap has a cylindricalrim at said outer end of said overflow cap, said test cap portion beingremovably connectable to said cylindrical rim.
 10. The system of claim 9wherein said test cap portion is integrally connected to saidcylindrical rim by a frangible seam for ease of removal of said test capportion from said other end of said overflow cap.
 11. The system ofclaim 10 further comprising a locking ring insertable over saidcylindrical rim upon removal of said test cap portion, said locking ringand said cylindrical rim having a lockable connection therebetween whenrotated in a locking direction relative to one another.
 12. The systemof claim 11 wherein said lockable connection comprises a pair of lockingtabs on said cylindrical ring, and a pair of locking ramps on saidlocking ring that are overlapped by said locking tabs when said lockingring is rotated in the locking direction relative to said overflow capto ramp said locking ring up against said overflow cap.
 13. The systemof claim 12 wherein said locking ring has a cross member containing ascrew hole for receiving a screw used to attach a cover plate to saidlocking ring.
 14. The system of claim 13 further comprising tabsextending outwardly from opposite sides of said locking ring for use inturning said locking ring relative to said overflow cap.
 15. The systemof claim 1 wherein a cross member extends across said overflow passageat said other end of said overflow cap, said cross member beingpermanently affixed to said other end of said overflow cap, and saidtest cap portion includes two test cap portion halves integrallyconnected to said other end of said overflow cap and opposite sides ofsaid cross member by frangible seams for ease of removal of said twotest cap portion halves from said other end.
 16. The system of claim 15further comprising a tab extending transversely of said cross member inaxially outwardly spaced relation therefrom, said tab having oppositeends integral with said test cap portion halves to prevent said test capportion halves from falling into said overflow passage upon removal ofsaid test cap portion halves from said other end of said overflow cap.17. The system of claim 16 wherein said cross member has a blind holefor receiving a screw used to attach a cover plate to said other end ofsaid overflow cap.
 18. The system of claim 1 wherein said test capportion has a lockable connection with said other end of said overflowcap.
 19. The system of claim 18 wherein said lockable connectioncomprises a pair of locking tabs on a cylindrical rim at said outer endof said overflow cap, and a pair of locking ramps on said test capportion that are overlapped by said locking tabs when said test capportion is rotated in a locking direction relative to said overflow capto ramp said test cap portion up against said overflow cap.
 20. Thesystem of claim 19 further comprising a locking ring insertable oversaid cylindrical rim of said overflow cap upon removal of said test capportion, said locking ring and said cylindrical rim having anotherlockable connection therebetween when rotated in a locking directionrelative to one another, said locking ring having a cross membercontaining a screw hole for receiving a screw used to attach a coverplate to said locking ring.
 21. The system of claim 20 wherein saidanother lockable connection comprises said pair of locking tabs on saidcylindrical rim, and another pair of locking ramps on said locking ringthat are overlapped by said locking tabs when said locking ring isrotated in the locking direction relative to said overflow cap to rampsaid locking ring up against said overflow cap.
 22. The system of claim1 wherein said other end of said overflow cap has a flange portionsurrounding said test cap portion that is engageable with a front sideof a bathtub around an overflow opening in the bathtub when said one endof said overflow cap is inserted through the bathtub overflow opening.23. The system of claim 22 wherein said conduit has a threaded end withan outer diameter greater than the diameter of the bathtub overflowopening.
 24. The system of claim 23 wherein said overflow conduitcomprises an overflow elbow.
 25. The system of claim 22 wherein saidflange portion of said overflow cap has a non-circular periphery forease of turning of said overflow cap for unscrewing said overflow capfrom said overflow conduit.
 26. The system of claim 1 further comprisinga gasket positionable over said one end of said overflow cap, saidgasket being compressible upon threading said overflow cap into saidoverflow conduit to form a fluid-tight seal between said overflowconduit and a back side of a bathtub.
 27. A bathtub having an overflowopening, and a waste and overflow system connected to said overflowopening, said waste and overflow system comprising an overflow conduit,an overflow cap having opposite ends, one of said ends extending throughsaid overflow opening into threaded engagement with said overflowconduit, an overflow passage extending through said overflow cap fromone end to the other, and a test cap portion removably connected to saidother end of said overflow cap for closing off said overflow passageduring pressure testing of the system, said test cap portion beingremovable from said other end of said overflow cap upon completion ofthe system pressure test to open up said overflow passage through saidoverflow cap.
 28. The bathtub of claim 27 further comprising a gasketpositioned over said one end of said overflow cap, said gasket beingcompressible upon threading said overflow cap and said overflow conduittogether to form a water-tight seal between said overflow conduit and aback side of said bathtub.
 29. The bathtub of claim 27 wherein saidother end of said overflow cap has a radial flange portion that isengageable with a front side of said tub upon threading said overflowcap and said overflow conduit together.
 30. The bathtub of claim 27wherein said test cap portion is integrally connected to said other endof said overflow cap by a frangible seam for ease of removal of saidtest cap portion from said other end.
 31. The bathtub of claim 30wherein said overflow cap includes a cross bar extending across saidoverflow passage, said cross bar being permanently affixed to said otherend of said overflow cap, and said test cap portion includes two testcap portion halves integrally connected to said other end of saidoverflow cap and opposite sides of said cross bar by frangible seams forease of removal of said two test cap portion halves from said other end.32. The bathtub of claim 31 further comprising a tab extendingtransversely of said integral cross bar in axially outwardly spacedrelation therefrom, said tab having opposite ends permanently affixed toeach of said test cap portion halves to prevent said test cap portionhalves from falling into said overflow passage upon removal of said testcap portion halves from said other end of said overflow cap.
 33. Thebathtub of claim 27 wherein said test cap portion is connectable to saidother end of said overflow cap by a mechanical connection that permitssaid test cap portion to be mechanically attachable and detachable fromsaid other end of said overflow cap.
 34. The bathtub of claim 27 whereinsaid other end of said overflow cap has a cylindrical rim surroundingsaid overflow passage through said overflow cap, said test cap portionbeing removably connectable to said cylindrical rim.